US20200260857A1 - Brush head manufacturing method, and brush head - Google Patents
Brush head manufacturing method, and brush head Download PDFInfo
- Publication number
- US20200260857A1 US20200260857A1 US16/761,570 US201816761570A US2020260857A1 US 20200260857 A1 US20200260857 A1 US 20200260857A1 US 201816761570 A US201816761570 A US 201816761570A US 2020260857 A1 US2020260857 A1 US 2020260857A1
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- United States
- Prior art keywords
- tuft
- merged
- retention elements
- bristle
- proximal end
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- A—HUMAN NECESSITIES
- A46—BRUSHWARE
- A46D—MANUFACTURE OF BRUSHES
- A46D3/00—Preparing, i.e. Manufacturing brush bodies
- A46D3/005—Preparing, i.e. Manufacturing brush bodies by moulding or casting a body around bristles or tufts of bristles
-
- A—HUMAN NECESSITIES
- A46—BRUSHWARE
- A46B—BRUSHES
- A46B9/00—Arrangements of the bristles in the brush body
- A46B9/02—Position or arrangement of bristles in relation to surface of the brush body, e.g. inclined, in rows, in groups
- A46B9/04—Arranged like in or for toothbrushes
-
- A—HUMAN NECESSITIES
- A46—BRUSHWARE
- A46D—MANUFACTURE OF BRUSHES
- A46D3/00—Preparing, i.e. Manufacturing brush bodies
- A46D3/04—Machines for inserting or fixing bristles in bodies
- A46D3/045—Machines for inserting or fixing bristles in bodies for fixing bristles by fusing or gluing to a body
Definitions
- the present disclosure is directed generally to methods for manufacturing a brush head assembly with anchor-free bristle tufts overmolded with an elastomeric matrix.
- the brush heads of both manual and power toothbrushes comprise bristles which are used to clean the teeth, tongue, and cheeks.
- the bristles are stapled, or anchored, into the neck portion of the brush head.
- the bristles are held in the head without staples, in methods commonly known as “anchor free tufting”.
- brush heads having anchor-free tufting There are several ways to manufacture brush heads having anchor-free tufting.
- groups, or tufts, of individual bristles are melted or fused together at one end, and then the bristle tufts are overmolded with a material that then hardens, forming a brush head.
- bristle tufts that are fused at one end are inserted into holes in the brush neck, and either the neck material is heated to shrink around the bristle tufts, or the brush neck with the inserted bristle tufts are overmolded.
- the manufacturing methods are slow, involve multiple steps and equipment, or have higher than acceptable failure rates, resulting in loose bristles or bristle tufts which can come out of the brush head during use.
- the present disclosure is directed to inventive methods for manufacturing a brush head with secured bristle tufts.
- Various embodiments and implementations herein are directed to manufacturing methods in which a tuft carrier with one or more retention elements and openings formed therethrough is used to retain tufts of bristles. Bristle tuft are then inserted into the openings in the retention elements. Once the bristle tufts have been inserted into the openings in the retention element, optionally, either or both ends of the bristle tufts can be trimmed or adjusted to achieve a desired length and/or contour to what will become the brushing surface of the brush head, and/or to achieve a uniform length of the bristle tufts on the proximal side of the retention element.
- proximal end of the bristle tufts or in some arrangements the proximal end of the bristle tufts and proximal side of the retention elements are then bonded together using for example, a laser, heat, chemical interaction or adhesive to form a proximal end head portion or a merged proximal end head portion.
- the retention element with melted or merged bristle tufts can be separated into individual merged tuft assemblies.
- a brush neck is positioned in or over a base plate that contains the merged tuft retention element(s).
- An elastomeric material is injected around a portion of the brush neck and merged tuft retention element(s), which, when cooled, forms an elastomeric matrix that bonds the neck, retention element and melted proximal end of the bristle tufts together to form a brush head.
- a method for manufacturing a brush head includes forming a plurality of retention elements each having one or more openings therethrough; positioning the retention elements into corresponding recesses of a base plate; inserting a bristle tuft into the opening of each corresponding retention element; bonding a proximal end of each bristle tuft to the corresponding retention element to form a merged proximal end head portion that secures the bristle tufts and the retention elements together as a plurality of merged tuft assemblies; positioning a neck of the brush head in relation to the merged tuft assemblies; and encompassing a platen of the neck and the merged tuft assemblies at least partially in a matrix.
- the bonding includes applying heat to a proximal side of the retention elements and the proximal end of the bristle tufts at a temperature sufficient to at least partially melt and join the bristle tufts to form the merged proximal end head portion.
- the bristle tufts and retention elements are made of a same or similar material having the same or a similar melting point.
- the bonding includes laser welding.
- the forming includes stamping the retention elements from a strip of backing material.
- the retention elements are formed as an interconnected web or a carrier plate.
- the forming includes removing excess material from the retention elements.
- the plurality of retention elements are included by a tuft carrier that comprises a carrier plate, one or more webbing links, or a combination including at least one of the foregoing.
- the method further includes stamping the tuft carrier to remove some or all of the carrier plate or the webbing links or to remove excess material to form the carrier plate or the webbing links.
- the retention elements are not removed from the recesses of the base plate during at least two of the inserting, bonding, positioning, and injecting steps performed sequentially.
- the openings in the retention elements are of differing shapes and sizes.
- the encompassing includes overmolding the merged tuft assemblies and the platen with the matrix.
- the encompassing includes injecting the merged tuft assemblies in the form of tuft spikes into the matrix after solidification of the matrix.
- the method further includes adjusting characteristics of the proximal end or a free end, opposite to the proximal end, of the bristle tufts.
- a brush head in another aspect, includes a plurality of merged tuft assemblies, each comprising: a bristle tuft comprising a plurality of bristle strands and having a free end and a proximal end; a retention element having an opening therethough configured to receive the bristle tuft; and a merged proximal end head portion formed by bonding the proximal end of the bristle tuft to the retention element; a neck having a platen; and a matrix at least partially encompassing the platen and the retention elements of the merged tuft assemblies.
- FIG. 1A is a perspective schematic representation of a brush head assembly in accordance with an embodiment.
- FIG. 1B is a perspective exploded view of the brush head assembly of FIG. 1A .
- FIGS. 2A and 2B are cross-sectional side views of schematic representations of merged tuft assemblies according to two embodiments disclosed herein.
- FIG. 2C is a bottom view of a bristle tuft engaged in a retention element of a tuft carrier.
- FIG. 2D is a top view of a merged proximal end head portion of a merged tuft assembly after laser welding.
- FIGS. 3A-3F are schematic representations of tuft carriers according to different embodiments disclosed herein.
- FIG. 4 is a representation of a stamping tool for manufacturing a brush head assembly of the present invention.
- FIGS. 5A-5C show successive steps of using a die block (or handling plate) to stamp out retention elements of a tuft carrier according to one embodiment disclosed herein.
- FIGS. 6A-6B show a handling plate and the handle plate engaged with a tuft carrier according to one embodiment disclosed herein.
- FIGS. 7A-7B show a handling plate and the handle plate engaged with a tuft carrier according to one embodiment disclosed herein.
- FIGS. 8A and 8B show a perspective view and a perspective cross-sectional view of a base plate according to one embodiment disclosed herein.
- FIG. 9 shows a base plate loaded in a tufting unit according to one embodiment disclosed herein.
- FIGS. 10A and 10B are cross-sectional views of a bristle tuft before and after a proximal end of the bristle tuft is trimmed.
- FIGS. 11A-11C illustrate tuft carriers after insertion and bonding of bristle tufts according to various embodiments disclosed herein.
- FIGS. 12A-12C illustrate a base plate having features for adjusting the free end of inserted bristle tufts according to various embodiments disclosed herein.
- FIGS. 13A-13C illustrate a top view and two cross-sectional views of various stages of manufacturing a brush head using a base plate according to one embodiment disclosed herein.
- FIGS. 14A and 14B are a cross-sectional side view and a side view of brush head assemblies according to embodiments disclosed herein.
- FIG. 15 is a flow chart illustrating a method of manufacturing a brush head according to one embodiment disclosed herein.
- FIG. 16 is a perspective schematic representation of a merged tuft assembly having a cap and of a laser welding process using a transparent component.
- FIG. 17 is a flowchart of a method for manufacturing a brush head assembly with bristle tufts retained in a retention element in accordance with an embodiment.
- FIG. 18 schematically illustrates a production line for manufacturing a brush head according to one embodiment disclosed herein.
- FIGS. 19A-19E illustrate a strip of backing material and resultant components at various manufacturing stages according to one embodiment disclosed herein.
- FIG. 20 is a flowchart of a method for manufacturing a brush head assembly in accordance with an embodiment.
- the present disclosure describes various embodiments of a method for manufacturing a brush head assembly with bristle tufts retained by anchor free tufting in a retention element secured in a molded elastomeric matrix. More generally, applicants have recognized the need for improvements in manufacturing methods and products made using anchor free tufting. By molding carriers, and in some arrangements, molding carriers from the same or similar material as the bristle tufts, efficiencies in manufacturing are achieved with improved product quality.
- the brush head assembly 10 may include, but is not limited to, a plurality of bristle tufts 21 disposed within a matrix 30 at a distal end of a neck 40 . That is, a distal portion 42 of the neck 40 , which may be referred to as a platen, may be at least partially enclosed in and connected to the matrix 30 .
- the platen 42 may be, or include, a generally flat portion that provides a hard, rigid, or otherwise reinforcing substrate that is aligned with the bristles of the merged tuft assemblies 20 to support the bristles of the brush head assembly 10 during use.
- the merged tuft assemblies 20 may include a tuft carrier 50 having one or more retention elements 52 , in which bristle tufts 21 are secured as discussed in more detail herein.
- the neck 40 can be coupled to, or form a part of, any manual or powered toothbrush shaft.
- the neck 40 may be configured to be removably coupled to an actuator or drive shaft (not shown) of a powered oral care device (e.g., electric toothbrush) now known or to be developed.
- FIGS. 2A and 2B Two examples for the merged tuft assemblies 20 are illustrated in FIGS. 2A and 2B , designated as merged tuft assemblies 20 A and 20 B, respectively.
- the reference numeral ‘ 20 ’ is intended to generally refer to any of the merged tuft assemblies disclosed herein, while the assemblies 20 A and 20 B are used herein to facilitate discussion with respect to particular embodiments. It is also to be appreciated that many components of the merged tuft assemblies 20 are shared throughout embodiments, and thus referred to with the same reference numerals.
- each bristle tuft 21 comprises a plurality of bristle strands 22 , which are secured in the retention elements 52 of tuft carrier 50 .
- Each bristle tuft 21 has a proximal end 23 and a free end 25 .
- the proximal end 23 of each bristle tuft 21 is retained within an opening 51 of each of the retention elements 52 of the tuft carrier 50 , while the free end 25 is located opposite to the proximal end 23 and forms the brushing surface force the brush head 10 when assembled.
- the bristle tufts 21 can be formed to a shape and diameter to match the size and shape of the openings 51 in the retention element 52 .
- the various components of the brush head 10 may take any desire size, shape, and/or orientation.
- the retention elements and bristle tufts contained therein can be round, pentagonal, hexagonal, or a variety of other shapes, such as squares, diamonds, heptagons, octagons, etc
- the retention elements 52 and the openings 51 therein can be of the same size, shape and arrangement as each other, or different shapes and sizes.
- the retention element 52 may have a first shape defining its periphery, while the opening 51 has a second, different shape defining the shape of the bristle tuft 21 inserted therethrough.
- the proximal end 23 of the bristle tufts 21 are bonded together to form a merged proximal end head portion 26 . That is, the merged proximal head portion 26 may be formed from fused material from the bristles 22 alone, or the bristles 22 together with a portion of the retention element 52 adjacent to the bristles 22 . In one embodiment, the bristle tufts and/or the retention elements 52 are bonded together by any suitable process such as welding (ultrasonic, laser, etc.), melting, adhesives, etc.
- the tuft carriers 50 and the bristle tufts 21 are preferably made from the same material, or materials having a similar composition.
- Plastics such as Acrylonitrile Butadiene Styrene (ABS), polyamide (PA) or nylon, polypropylene, or variations or combinations of these or other materials can be used. Particularly useful are combinations of materials that have a similar co-efficient of melting to facilitate bonding by melting and cooling at a similar temperature and rate.
- the bristles 22 are formed from PA, while the retention elements 52 are formed from a PA/ABS blend.
- a laser welding process is used, which can effectively melt and bond the bristle tufts 21 and retention elements 52 together to form the merged proximal head portion 26 as a seal that completely seals across the opening 51 at the proximal end 23 of the merged tuft assemblies 20 .
- the laser concentrates the welding energy more precisely, while enabling more exact application of heat, so that the proximal ends 23 of the bristle tufts 21 and the proximal side 53 of retention elements 52 melt to from a substantially uniform merged proximal end head portion 26 , e.g., as shown in FIG. 2D .
- the tuft carriers 50 and/or retention elements 52 can be formed in a variety of ways, such as molding, stamping, etc., as discussed in more detail herein.
- Various embodiments for the tuft carriers 50 can be appreciated in FIGS. 3A-3F .
- the reference numeral ‘ 50 ’ as used herein is intended to refer generally to all embodiments of tuft carriers disclosed or envisioned, while alphabetic suffixes (e.g., ‘A’, ‘B’, etc.) have been provided to facilitate discussions of particular embodiments shown in the Figures. A similar naming style may be utilized with respect other components herein.
- a tuft carrier 50 A in FIG. 3A comprises a single one of the retention elements 52 , which will hold a at least one of the bristle tufts 21 in the opening 51 of the retention element 50 A.
- FIGS. 3B and 3C respectively show a tuft carrier 50 B and a tuft carrier 50 C that each comprises a carrier plate 54 having a plurality of the retention elements 52 connected together, e.g., arranged in a shape of the final brush head or some portion thereof.
- FIGS. 3D-3F tuft carriers 50 D, 50 E, and 50 F are respectively shown.
- Each of the tuft carriers 50 D- 50 F comprise a tuft carrier web that has a plurality of individual retention elements 52 connected to each other by a series of strands or webbing links 55 .
- the retention elements 52 can be separate discrete units, or interconnected together, such as by the carrier plate 54 or the webbing links 55 .
- the retention elements 52 and/or the openings 51 of the tuft carriers 50 D- 50 F may be arranged in the desired pattern for the tufts 21 when the brush head is fully assembled, or some portion thereof.
- the tuft carriers 50 are formed via a molding operation, such as injection molding.
- the actual shape and size of the tuft carrier 50 , the number, size, and shape of the openings 51 , etc., can be set and determined by the mold used to form the carrier 50 .
- the carrier 50 Once the carrier 50 has been formed and cooled, it can optionally be removed from the mold, and is ready for further processing, either immediately, or at a later time and/or place.
- the tuft carrier 50 may be removed prior to assembly of the retention elements 52 in the brush head 10 .
- the removal of excess material is performed by a stamping tool 100 shown in FIG. 4 .
- the stamping tool 100 may include a press, ram, stamp, or die that forcibly engages the tuft carrier 50 placed in a die block or handling plate 101 , as shown in FIG. 5B to cut apart, disconnect, or otherwise separate one or more portions of the tuft carrier 50 from each other.
- the die block 101 or handling plate has a series of openings 103 configured to match the retention elements 52 in the tuft carrier 50 in size, shape and arrangement.
- the openings 103 of the die block or handling plate 101 of FIGS. 5A-5C corresponds to the size, shape, and layout of the tuft carrier 50 C from FIG. 3C .
- the retention elements 52 of the tuft carrier 50 C can be inserted into the openings 103 of the die block handling plate 101 .
- the die block or handling plate 101 together with the tuft carrier 50 C, can be loaded into, and stamped by, the stamping tool 100 . As shown in FIG. 5C , the stamping operation may disconnect or separate the retention elements 52 from excess material 59 .
- the excess material 59 may be recycled or discarded, while the retention elements 52 may remain in the openings 103 of the handling plate 101 , or be removed, for further processing.
- the handling plate 101 may be utilized to facilitate the general handling of the tuft carrier 50 and/or the loading of the tuft carrier 50 into other tools, such as a tufting unit, or other equipment used to create a finished brush head 10 .
- the handling plate 101 with the tuft carrier therein can be positioned on top of a base plate 110 with openings of similar size and shape in similar positions and the tuft carrier may be transferred from the handling plate into the base plate 110 . It is also noted that some or all of the excess material 59 of tuft carrier 50 may be removed via other processes, e.g., cutting, or via multiple successive processes, at this step or other steps of the manufacturing process.
- a die block or handling plate 101 B is illustrated in FIGS. 6A-6B .
- the handling plate 101 B includes openings 103 B, which correspond in shape, size, and layout to the retention elements 52 of the tuft carrier 50 D of FIG. 3D , as shown in FIG. 6B .
- the openings 103 B in the die block 101 B facilitate stamping of the tuft carrier 50 D directly into the die block 101 .
- the handling plate 101 B may include a set of grooves or recesses 104 , which are shaped and sized to receive the webbing links 55 of the tuft carrier 50 D.
- the grooves 104 may assist in positioning and holding the tuft carrier 50 D during manufacturing.
- the handling plates 101 disclosed and envisioned herein may be removably separated from the base plate 110 or other components of the stamping tool 100 , e.g., to facilitate further processing of the corresponding tuft carrier conveyed by the handling plate 101 .
- the handling plate 101 B, together with the tuft carrier 50 stamped into the handling plate, left behind in the grooves 104 may be separated from the excess material, if desired, for further processing.
- FIGS. 7A-7B A handling plate 101 C according to another embodiment is illustrated in FIGS. 7A-7B .
- the handling plate 101 C includes an opening 103 C, which corresponds in general shape, size, and/or layout to the carrier plate 54 of the tuft carrier 50 B of FIG. 3B (as opposed to the individual retention elements 52 ).
- the stamping tool 100 may be configured, with a punch or stamping element to remove only a portion of the carrier plate 54 so as to change the shape of tuft carrier 50 B to the shape of the tuft carrier 50 F of FIG. 3F .
- excess portions of the carrier plate 54 may be removed to leave behind only the webbing links 55 .
- the carrier plate 54 may be utilized without removing any excess portions.
- the tuft carrier 50 is formed by overmolding the tuft carrier 50 directly onto the corresponding handling plate 101 .
- the handling plate 101 together with the unprocessed instance of the tuft carrier 50 , can be directly placed on the base plate 110 and processed by manufacturing equipment, e.g., stamped by the stamping tool 100 .
- the handling plates 101 may be made of any desired material, such as a metal or other rigid material to facilitate handling of the tuft carrier 50 when engaged with the handling plate 101 , as well as to promote reusability of the handling plate 101 for multiple stampings or other manufacturing processes.
- FIG. 8A One embodiment for a base plate 110 is shown in FIG. 8A and cross-sectionally in FIG. 8B .
- the base plate 110 includes a recessed area 111 configured to receive the handling plates 101 or other manufacturing plates as discussed herein (as shown in FIG. 9 ).
- the base plate 110 together with the handling plate 101 placed in the recessed area 111 , can be used during stamping to stamp the retention elements 52 directly into corresponding openings 109 in the base plate 110 .
- the base plate 110 in FIG. 8B is also illustrated having the retention elements 52 already inserted in the openings 109 , via stamping as discussed above, or by some other process such as manual insertion.
- the tuft carrier 50 may comprise individual retention elements 52 , such as shown in FIG. 8B , or the tuft carrier 50 b , 50 c , may comprise a plurality of the retention elements 52 connected by the carrier plate 54 , of the tuft carrier 50 d , 50 e , 50 f , may comprise a plurality the retention elements 52 connected by webbing links 55 .
- the base plate 110 has openings 109 that correspond to each of the openings 51 in the retention elements 52 .
- the diameter or dimensions of the openings 109 may be configured such that the retention elements 52 are held by the base plate 110 in a desired position (e.g., the openings 109 may be tapered from top to bottom).
- the configuration of the openings 109 is useful for defining the shape, length, configuration, and cross-sectional shape of the bristle tufts 21 that will be inserted during subsequent steps of the manufacturing process.
- the base plate 110 may include an adjustment feature configured to assist in defining the length and/or contour of the free ends 25 of the bristle tufts 21 , such as a contour insert 114 .
- FIG. 9 illustrates a tufting unit 130 according to one embodiment.
- the tufting unit 130 may be provided operated to form a plurality of the bristle strands 22 into the bristle tufts 21 , which are inserted into each of the plurality of openings 51 in the retention elements 52 , as shown in FIG. 10A .
- the tufting unit 130 may include a tuft inserter 132 that can be aligned with a corresponding openings 103 in a handling plate 101 that is inserted in the base plate 110 (e.g., held in the recessed area 111 ).
- the die block or handling plate 101 includes a plurality of openings 103 therethrough.
- the openings 103 in the handling plate 101 are aligned with the openings 51 in the tuft carrier 50 , and the openings 109 in the base plate 110 .
- the tufting unit 130 forcibly injects the bristles therein (e.g., mechanically, via pressurized air, etc.) to form bristle tufts 21 of a shape and size that corresponds with the openings.
- the handling plate 101 may be a die plate, a guide plate, or a different plate. It is noted that tufting may occur prior to the aforementioned stamping or cutting of tuft carriers, if desired.
- the bristle tufts 21 must be of the proper shape, size, and diameter to fit into each respective opening.
- the ends of the bristle tufts 21 that are inside the base plate 110 will become the free end 25 of the bristle tufts 21 in the brush head assembly 10
- the portion of the bristle tufts 21 that project above the base plate 110 such as shown in FIG. 9
- proximal ends 23 of the bristle tufts 21 may optionally need to be trimmed to a uniform height to ensure a proper sealing during the subsequent bonding step.
- a cutting plate 116 having a height H can be placed in the recess 111 on the base plate 110 at the proximal end 23 of the tuft 21 .
- the cutting plate 116 may be the same plate as the handling plate 101 , or may be a different plate.
- a knife or cutting implement 117 can be used to trim the length of the bristle tuft 21 by removing the excess portion of the bristle tuft 21 protruding above the plate 116 . In this way, as shown in FIG.
- the length of bristle tuft 21 extending out from a proximal side 53 of the retention element 52 will approximately equal the height H of the plate 116 when the plate 116 is removed.
- this preset length of the proximal end 23 of the bristle tuft 21 can be useful to assist the consistent and predictable creation of the proximal end head portion 26 during bonding.
- the proximal ends 23 of the bristle tufts 21 can be bonded to the proximal side 53 of retention elements 52 , e.g., by melting, welding, adhering, or other technique, to form the merged proximal end head portion 26 as noted above with respect to FIGS. 2A-2B and also shown in FIGS. 11A-11C .
- FIGS. 11A-11C Three different examples of the tuft carriers 50 after tufting are shown in FIGS. 11A-11C . More particularly, FIG. 11A illustrates the tuft carrier 50 D tufted with the bristle tufts 21 , which extend into openings of the base plate 110 .
- FIG. 11A illustrates the tuft carrier 50 D tufted with the bristle tufts 21 , which extend into openings of the base plate 110 .
- FIG. 11B illustrates the tuft carrier 50 B tufted with the bristle tufts 21 while carried by the handling plate 101 C.
- FIG. 11C illustrates the tuft carrier 50 A (a single one of the retention elements 52 ) with the bristle tuft 21 melted to form a merged proximal end head portion 26 from at least a portion of the bristle tuft 21 and a portion of the proximal end of the retention element 52 .
- bonding is accomplished by melting the bristle strands 22 , alone or together with a portion of the retention element 52 .
- Heat can be supplied by a heat source that comes into direct physical contact with the proximal end 23 of the bristle tufts and/or the proximal side 53 of the retention elements 52 , such as a laser.
- the heat can be supplied by heated air or any of a variety of other heat sources that can be in direct physical contact, merely adjacent, or directed.
- forming the bristle strands 22 and the retention elements 52 from the same or a similar material composition may advantageously improve bonding by utilizing a same or similar melting point.
- tuft bores 112 are arranged as blind holes that terminate within the base plate 110 .
- the bottom surface of the blind holes can be set as a predefined distance from openings 109 , in which the retention elements 52 are be seated during tufting. That is, the bottom of each blind hole provides a stop for the portion of the bristle strands 22 that will ultimately become the free end 25 of the bristle tufts 21 in the completed brush head so that the bristle tufts 21 are maintained at the proper length during the manufacturing process.
- the blind holes also support the bristle strands 22 during the manufacturing process when the bristle strands 22 are inserted (e.g., via the tufting unit 130 ).
- the tuft bores 112 arranged as blind holes can be set to different shapes, sizes, or contours.
- a first blind hole 118 A is illustrated as slightly larger in diameter than the others
- a second blind hole 118 B is illustrated as slightly shorter than the others and with a curved bottom surface to create a curved contouring for the free end 25 of the bristle tuft 21 that is inserted into the blind hole 118 B.
- the base plate 110 in FIG. 12B is illustrated as including a contour insert 114 also shown in FIG. 8B .
- the contour insert 114 may be used to define the shape of the free end 25 of the bristle tufts 21 in the brush head assembly 10 .
- the contour insert 114 shown in FIG. 12B would generate a finished brush head that has a shape of bristle tufts that vary in length and surface angle, as set by the tufts 21 engaging against a surface 114 a of the contour insert 114 .
- contour insert 114 may be arranged as a removable and interchangeable component so a variety of desired shapes of completed brush head bristles can be achieved with the same base plate 110 .
- each of the tuft bores 112 may be provided with a pin 116 of the same shape and diameter as the tuft bores 112 .
- the pins 116 may be movable within the tuft bores 112 to enable the length of the tuft bores 112 to be adjustably set. Pins having different surface angles can be included to change the contouring of the brushing surface resulting from the free ends 25 .
- the pins 116 generally serve the same purpose and function as the contour insert 114 and the blind holes 118 , e.g., to form the desired shape, length, and contours of the bristle field and/or brushing surface of the completed brush head.
- FIG. 13A shows a top view of the base plate 110 having the tuft bores 112 and the recesses 109 formed therein as described above, i.e., for receiving the bristle tufts 21 and the retention elements 52 , respectively.
- the merged tuft assemblies 20 are fully formed, and can be positioned with the retention elements 52 in the recesses 109 and the free ends 25 of the bristle tufts 21 in the tuft bores 112 .
- the base plate 110 may also include a recess or cavity 120 in the general shape of the brush head 10 neck 40 and/or the matrix 30 .
- the neck 40 may be positioned to align the platen 42 in relation to the merged proximal end head portions 26 of the merged tuft assemblies 20 .
- the cavity 120 may properly align the platen 42 of the neck 40 with the tuft assemblies 20 when the neck 40 is placed in the cavity 120 .
- any desired prefabricated parts e.g., electronic parts, additional rings, springs, or any other components
- Any such parts can be molded into the final brush head as described in subsequent steps herein.
- the components may be overmolded by the matrix 30 by injecting material, e.g., in a liquid or flowable state, into the space formed between the platen 42 and the merged proximal end head portions 26 of the merged tuft assemblies 20 .
- the matrix 30 solidifies to secure the neck 40 and the tuft assemblies 20 together by at least partially encompassing or encapsulating the platen 42 and the tuft assemblies 20 , as shown in FIG. 13C , thereby forming the brush head assembly 10 .
- the matrix 30 is preferably made from an elastomeric material such as a flexible thermoplastic elastomer (TPE) or silicone rubber.
- FIGS. 14A and 14B respectively illustrate additional examples of the brush head 10 when completed.
- a method 200 for manufacturing one or more of the various brush head embodiments 10 and implementations described or otherwise envisioned herein is a method 200 for manufacturing one or more of the various brush head embodiments 10 and implementations described or otherwise envisioned herein.
- a tuft carrier 50 is formed, such as by molding by any known molding process.
- the tuft carrier includes one or more retention elements 52 having an opening 51 formed therethrough.
- the tuft carrier may be processed to alter, set, or define the size or shape of the tuft carrier, or the retention elements or openings therethrough.
- the tuft carrier may be stamped or cut to remove excess material 59 .
- the tuft carrier may be a carrier plate 54 further processes so that one or more webbing links 55 that are formed, shaped, resized, or removed in the step 220 (e.g., with the stamping tool 100 , the handling plate 101 , or as otherwise discussed with respect to FIGS. 4-7B ).
- the retention elements of the tuft carrier are positioned in corresponding recesses 109 of a handling plate 110 .
- the steps 220 and 230 are essentially combined in that the retention elements are directly stamped into the recesses of the handling plate simultaneously as the excess material is removed (as discussed with respect to FIGS. 4-7B ).
- bristles are arranged in tufts and inserted (e.g., via the tufting unit 130 ) through the openings 51 in the retention elements 52 .
- a proximal end 23 and/or a free end 25 opposite to the proximal end of the bristle tufts 21 may be adjusted in length, shape, size, contour, etc.
- a base plate may include an adjustment feature such as an insert having a contoured surface 114 , or blind holes 118 and pins 119 for receiving and setting the contour of the free ends.
- the proximal ends of the bristle tufts may optionally be cut or trimmed to achieve a desired height using a cutting plate 116 and a knife or cutting implement 117 .
- the proximal end 23 of the bristles 22 of the bristle tufts 21 are bonded together and/or bonded to at least a portion of the proximal side of the retention element 50 to form a merged proximal end head portion 26 .
- each corresponding pair of the bristle tufts and the retention elements form a merged tuft assembly 20 .
- bonding is achieved by applying heat to the proximal end of the bristle tufts and the retention elements to melt the components together. The heat can be supplied by a heat source that comes into direct physical contact with the proximal end of the bristle tufts and/or the retention elements.
- the heat can be supplied by heated air or any of a variety of other heat sources that can be in direct physical contact, merely adjacent, or directed.
- the bristle strands and the retention elements from material having the same or a similar composition, and therefore the same or similar melting point, good bonding can be facilitated.
- the tuft carrier can be processed to remove any excess material. For example, as discussed above with respect to step 220 , this may include removing a portion or all of a carrier plate, webbing link, etc. As also discussed above, step 270 may not be performed, e.g., if the entirety of the carrier plate 54 is included in the brush head assembly 10 when fully assembled.
- the tuft assemblies can be inserted into the base plate (if not already installed) and a neck 40 for the brush positioned relative to the tuft assemblies.
- this may include placing the neck in a corresponding cavity 120 of the base plate, which aligns a platen 42 portion of the neck 40 with respect to the merged tuft assemblies.
- a matrix material 30 is overmolded about at least a portion of the merged tuft assemblies and the neck by injecting material into the space between the neck and the merged tuft assemblies.
- the matrix may include an elastomeric material. Once solidified, the matrix at least partially encompasses or encapsulates the merged tuft assemblies and the neck together, thereby forming the brush head assembly.
- the same handling plate or base plate may be utilized for multiple different manufacturing steps, such as molding, stamping, tufting, bonding, trimming/adjusting bristles, and/or overmolding.
- partially-manufactured components may be transferred from one handling plate or base plate to a different handling plate or base plate.
- each of the steps in method 200 are optional and/or may be completed in an order other than that shown.
- these features enable flexibility in the time and location for any of the manufacturing steps, while also permitting each step to immediately follow the next if desired.
- laser welding may be particularly advantageous in some embodiments for bonding the bristles and retention elements together.
- Laser welding will consume at least a portion of the proximal end 23 of the bristles 22 as well as adjacent portions of the retention elements 52 in forming the merged proximal head portion 26 as a completely sealed unitary element.
- the laser welding can accordingly be operated at some pre-specified performance characteristics (e.g., laser beam wavelength, resultant temperature of the heated materials, pulsation frequency or duration of continuous operation, beam diameter, speed at which the beam is moved across the proximal end 23 , etc.) to melt the corresponding materials to a predictable depth and/or with a predictable depth profile(s) across the width (lateral/radial direction) of each of the tuft assemblies 20 .
- Laser welding operations may be configured with respect to one or more weld zones.
- the weld zones may include a first weld zone adjacent the proximal side 53 of the retention element 52 , in which only material from the retention element 52 is melted and reformed, i.e., without integrating any of the bristle strands 22 therein.
- a second zone may be formed laterally or radially inward of the first zone, in which both a portion of the retention element 52 and the bristle strands 22 are melted and integrated together.
- a third zone may be formed where only the bristles 22 are melted and integrated together, i.e., without integrating any material from the retention element 52 .
- the second zone can advantageously fuse together materials from both the retention elements 52 and the bristles 22 and assist in integrating the first and third zones together as a continuous, unitary, sealed structure, e.g., the merged proximal head portion 26 .
- Any of the weld zones discussed above may be formed to preselected dimensions (e.g., lateral distance and/or longitudinal depth) and/or with some preselected dimensional profile(s) in the corresponding zone, e.g., a gradient laterally/radially across the tuft assembly 20 and/or across any of the zones.
- the third zone (including just the material from the bristles 22 ) is expected in many embodiments to be the largest zone, depending on the cross-sectional size of the tufts 21 and the thickness of the retention elements 52 .
- the selected welding energy or energies, the area/volumes to which the energy/energies are directed, the duration the energy/energies are applied, and other parameters may be varied across the tuft 21 or the tuft carrier 50 and/or across a particular tuft of a particular retention element 52 of the tuft carrier 50 .
- the parameters of the welding may be configured so as to provide strong, complete, sealed and otherwise desired welds for each tuft-retention element.
- particular welding parameters may be adjusted to respond to one or more of various factors, such as: (a) desired shape/dimensions of a weld to set a tuft retention force enabled by the weld and other structural and performance goals relating to the weld; (b) a tuft's shape, dimensions, size, etc.; (c) a tuft carrier or retention element shape, dimensions, size, etc.; (d) alignment/orientation of a tuft with respect to its retention element (e.g., the distance(s), such as the height H, that filaments protrude from the proximal end of the retention element); (e) the alignment/orientation of the tuft carrier or tuft-retention element to the platen, e.g., to set performance characteristics of the tufts after final assembly of the brush head; (f) filament(s) shape, structure(s), type, materials, etc.; and/or (g) the carrier/retention element's shape, structure(s), type, materials, etc.
- the welding configuration may be optimized, e.g., to arrive at desired and proper welds in a minimum or otherwise desired amount of time, or energy (e.g., to minimize or prevent burning or other activity that might change the nature of the weld or any material).
- One or more selected welds may be performed by introducing an auxiliary material to selected area of the welding.
- an auxiliary material may be introduced at the proximal end of selected or all filaments so that, with welding, a weld is provided that combines the bristles 22 with the auxiliary material and the retention element 52 in locations sufficiently proximate to the retention element 52 .
- the introduction of the selected material may be accomplished by applying the auxiliary material, e.g., as a thread, powder, liquid, etc. to the welding area in a selected mass or volume during welding.
- the auxiliary material may be the same or similar material as the bristle strands 22 , or the retention element 52 , some combination of these, or neither of these.
- one or more plates, caps, coverings, coatings, or other solid volumes comprising a defined amount of an auxiliary material may be applied on, over, or adjacent the selected area(s) for welding.
- its selected area may provide for it to extend beyond the tuft perimeter (e.g., laterally or radially) so as to cover the merged proximal end head portion 26 .
- the plate forms a cap 27 , as shown in FIG. 16 , which covers all, or substantially all, of the merged proximal end head portion 26 of the retention element 52 and the tuft 21 after welding.
- the seal provided by the welding may be enhanced, e.g., so as to impede or prevent incursion of other materials between the bristles 22 and/or the retention element 52 during subsequent overmolding or other assembly processes.
- the laser welding process is performed using a plate or material that is transparent to the beam of the laser.
- the laser may pass through the plate so as to weld the tuft and retention element and, in so doing, generate thermal energy sufficient to join the plate to the retention element 52 and/or the tuft 21 .
- the plate may be placed over the merged proximal end head portion 26 with clamping pressure applied.
- the cap 27 may be made from a material that is transparent to a beam 99 from a laser device, such that the beam 99 passes through the cap 27 and melts the bristle tuft 21 and/or the retention element 52 together at an outer surface 26 ′ of the merged proximal end head portion 26 .
- the heat generated at the outer surface 26 ′ can be sufficient to also bond the cap 27 to the bristle tuft 21 and/or the retention element 52 , thereby sealing and/or forming a part of the merged proximal end head portion 26 .
- a method 300 for manufacturing merged tuft assemblies 20 is a method 300 for manufacturing merged tuft assemblies 20 according to the embodiments and implementations described or otherwise envisioned herein. It is to be understood that the steps of the method 300 may be generally interchanged, or inserted, as applicable, with or between the steps of other methods disclosed herein, such as the method 200 . Likewise, the steps of other methods disclosed herein may be interchanged and/or inserted into the method 300 .
- a tuft carrier 50 comprising one or more retention elements 52 is provided.
- a plurality of bristle tufts 21 are provided, each of which comprises a plurality of bristle strands 22 .
- At step 320 of the method 300 at least one of the bristle tufts is inserted into an opening 51 of each of the retention elements of the tuft carrier.
- the length, contouring, or configuration of a proximal end 23 or a free end 25 of the bristle tufts may be trimmed or otherwise adjusted (e.g., as discussed with respect to step 250 of the method 200 ).
- a laser is utilized to weld the proximal end of the bristle tuft, or the proximal end of the bristle tuft and at least a portion of the proximal side 53 of the retention element together.
- the laser welding creates a proximal head portion 26 .
- Step 330 may include adding an auxiliary material (e.g., the cap 27 ) to assist in creating or sealing the weld.
- the welded tuft assembly can be further processed, either immediately thereafter or at another place and time.
- the welded tuft assemblies can be positioned relative to a neck of a brush head (e.g., the neck 40 ) and overmolded, together with the neck, by a matrix (e.g., the matrix 30 ) to form a completed brush head (e.g., the brush head 10 ).
- the tuft carriers 50 may be formed by stamping.
- a manufacturing production line 150 for manufacturing brush heads, e.g., the brush head 10 , utilizing stamping is illustrated in FIG. 18 .
- Various steps or stages employed by the production line 150 are also best appreciated in FIGS. 19A-19E , which are marked with the corresponding stage number from FIG. 18 in brackets.
- the production line 150 is provided with a backing material 60 in a blank form.
- the backing material 60 may be provided from a roll 151 , or in some other form such as a strip 151 a , plate, etc. (not shown).
- the backing material 60 may have a width and thickness sufficient from which to produce the retention elements 52 .
- the backing material 60 may be formed as a length of material such that retention elements 52 for a number of brush heads may be successively produced from the same piece of backing material, e.g., as the backing material 60 is unspooled from the roll 151 , or a strip of backing material 151 a (not shown) is fed to the manufacturinc equipment.
- the backing material 60 may have one or more guide holes 61 to assist in transitioning the backing material 60 between the different pieces of manufacturing equipment, and/or to keep the backing material 60 at the proper position and tension on the manufacturing equipment, e.g., by engaging the holes 61 with corresponding pins of the manufacturing equipment.
- a plurality of openings 62 is stamped through the backing material 60 .
- different sizes, shapes and placements of openings 62 can be stamped into the backing material 60 .
- the openings 62 may each, and/or together, be arranged in sizes, shapes, and/or patterns to reflect the planned arrangement of bristles tufts 21 in the brush head assembly 10 when completed.
- the retention elements 52 are formed from the backing material 60 with each opening 62 providing a means for inserting a bristle tuft therethough so that the bristle tuft may be secured with or to through the retention elements 52 .
- Stage [ 2 ] may be carried out using a die and/or stamping press 152 . If different final bristle configurations are desired, different stamp dies can be used for the various configurations.
- the backing material 60 and/or portions thereof may be engaged in or on a mold or based plate 110 .
- the backing material 60 Once the backing material 60 has been stamped, it is ready for further processing, either immediately, or at a later time and/or place. If at a later time and/or place, the stamped backing material 60 can be rolled or stacked and unrolled or unstacked again later for further processing on the same or different manufacturing equipment.
- the backing material 60 may stay in the mold (e.g., the base plate 110 ) during multiple stages, or may be transferred between different molds (e.g., the base plate 110 ), e.g., specifically arranged for each stage, as desired.
- each bristle tuft 21 is inserted into the plurality of openings 62 in the backing material 60 .
- each bristle tuft 21 must be of the proper size to fit into each respective opening 62 and/or the size and shape of the openings 62 define the respective shape and size of the corresponding bristle tuft 21 when the openings 62 are filled with the bristle strands 22 .
- the proximal end 23 and free end 25 may be adjusted via any manner described herein, e.g., via a contour plate, pins, blind holes, cutting plate, knife, etc.
- a portion of the tufts 21 is illustrated as protruding from a proximal side 63 of the backing material 60 at stage [ 3 ], and this protruding portion is removed at stage [ 3 . 1 ].
- the protruding portion may be trimmed to a predetermined height, e.g., in order to facilitate later bonding processes, particularly melting or other processes that tend to partially consume the bristle strands 22 during bonding.
- the cutting or trimming of the bristles 22 may be accomplished by a knife or other cutting tool, e.g., running along the surface of the proximal side 63 of the backing material 60 .
- the proximal ends 23 of the plurality of bristle tufts 21 are bonded together, which may include bonding the tufts 21 with or to at least a portion of the surrounding backing material 60 .
- sufficient heat to melt the components together may be applied to form the merged proximal end head portion 26 as discussed above with respect to FIG. 2 .
- the merged proximal end head portion 26 may be formed as a combination of one or more of at least a portion of the proximal side 63 of the backing material 60 and at least a portion of the proximal end 23 of the bristle tufts 21 merged together.
- Bonding can be achieved using a heat source 155 , such as a heated press, ram, or pin, which comes into direct physical contact with the proximal end 23 of the bristle tufts 21 and/or the proximal side 63 of the backing material 60 .
- bonding cana be achieved using heated air, a welding laser, chemical fusing, or a variety of any other heat source.
- the backing material 60 and bristle tufts 21 may be made of material having the same or a similar composition, such as ABS, nylon, polypropylene, or variations or combinations of these materials.
- a tuft carrier web 28 may be formed as a group of the tuft retention elements 52 interconnected by strands or webs (e.g., in the final bristle tuft pattern for the brush head 10 ). Enlarged versions of the tuft retention elements 52 and/or the tuft carrier web 28 at stage [ 5 ] is illustrated in FIG. 19D .
- Stage [ 5 ] may include a pre-cutting operation in which the tuft retention elements 52 and/or the tuft carrier web 50 ′ is still attached to the backing material 60 via one or more strands or webs.
- stage [ 5 ] of manufacturing is not utilized.
- a carrier plate 29 of merged tuft assemblies is created, as best shown in FIG. 19C at stage [ 4 ].
- manufacturing proceeds from stage [ 4 ] directly to stage [ 6 ], and the carrier plate 29 of merged tuft assemblies is removed from the backing material, 60 as described below.
- individual merged tuft assemblies 20 and/or tuft carrier webs 28 of merged tuft assemblies, or carrier plates 29 of merged tuft assemblies may be completely removed from the backing material 60 .
- An enlarged view of the tuft carrier web 28 is shown in FIG. 19E .
- the neck 40 is formed according to any desired known or future developed standard manufacturing technique, e.g., by molding the neck 40 from plastic using a mold.
- the neck 40 and the merged tuft assemblies 20 e.g., separately or in one of the tuft carriers 50 such as the tuft carrier web 28 or tuft carrier plate 29 ) are positioned relative to each other and overmolded by the matrix 30 .
- the backing material 60 is stamped in such a way, e.g., at stage [ 2 ], such that the excess portions 64 of the backing material 60 are removed prior to tufting.
- the tuft retention elements 52 and/or the tuft carrier web 50 ′ are tufted and then bonded to the tufted bristles, instead as described above.
- the retention elements 52 , the tuft carrier web 28 , or carrier plate 29 can be completely cut out of the backing material 60 (e.g., as discussed with respect to stages [5-6]), and further processing (e.g., insertion of bristle tufts in accordance to stage [ 3 ], bonding or melting in accordance with stage [ 4 ], over molding in accordance with stage [ 8 ], etc.), can be completed (e.g., after cutting them out from the backing material 60 , the retention elements 52 and/or the carrier web 28 or carrier plate 29 may be maintained in the same mold until completion).
- the partially-processed backing material 60 may be transferred between different molds or pieces of equipment at the same or different locations, facilities, and/or times.
- a method 400 is provided for manufacturing one or more of the various brush head 10 embodiments and implementations described or otherwise envisioned herein.
- the steps of the method 400 may be generally interchanged, or inserted, as applicable, with or between the steps of other methods disclosed herein, such as the methods 200 or 300 .
- the steps of other methods disclosed herein may be interchanged and/or inserted into the method 400 .
- a strip 151 a or roll 151 of backing material is provided as described with respect to stage [ 1 ] above.
- a plurality of openings 62 is formed through the backing material of a size, shape and pattern to reflect the planned arrangement of bristles in the completed brush head assembly 10 as described with respect to stage [ 2 ] above).
- the backing material is stamped or cut in such a way that excess portions 64 of the backing material are removed to form one or more separate tuft retention elements 52 and/or an interconnected web of tuft retention elements 28 .
- the retention elements and/or carrier web may be completely cut out of the backing material before subsequent processing.
- a bristle tuft 21 comprising a plurality of the bristle strands 22 , is inserted into each of the openings formed in step 420 .
- the proximal end 23 and/or the free end 25 of the bristle tufts may be trimmed or adjusted to a set a desired length and/or contouring (e.g., using the contouring plate as discussed herein).
- the bristles are bonded.
- the step 460 may include applying heat to the proximal end of the plurality of bristle tufts 21 to melt the bristles and/or the bristles and the backing material together to form a proximal end head portion 26 .
- laser welding, adhesives, or other bonding techniques may be used for the bonding step.
- Optional step 470 resembles optional step 430 and may be performed if step 430 was not performed previously. That is, at step 470 , once the merged proximal end head portion of the merged tuft assembly is formed, excess portions of the backing material can be removed to form separate tuft retention elements and/or an interconnected group of tuft retention elements arranged in a tuft carrier web. In step 480 of the method 400 , the completed tuft retention elements and/or tuft carrier web can be cut out of the backing material. It is noted that the step 480 may occur directly after, or as part of, the step 430 if desired.
- a platen portion 43 of a brush head neck 40 is positioned in relation to the merged tuft assemblies 20 by placing the tuft carrier assemblies 20 as described above.
- a matrix 30 can then be injected into the space created between the tuft carrier assemblies and the neck of the brush head.
- the matrix when solidified, encompasses or encapsulates at least a portion of the neck and the merged tuft assemblies, to form the completed brush head assembly (e.g., the brush head 10 as shown in FIG. 1A ).
- the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements.
- This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.
- inventive embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed.
- inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein.
Abstract
Description
- The present disclosure is directed generally to methods for manufacturing a brush head assembly with anchor-free bristle tufts overmolded with an elastomeric matrix.
- The brush heads of both manual and power toothbrushes comprise bristles which are used to clean the teeth, tongue, and cheeks. In some toothbrushes, the bristles are stapled, or anchored, into the neck portion of the brush head. In other toothbrushes, the bristles are held in the head without staples, in methods commonly known as “anchor free tufting”.
- There are several ways to manufacture brush heads having anchor-free tufting. In one method, groups, or tufts, of individual bristles are melted or fused together at one end, and then the bristle tufts are overmolded with a material that then hardens, forming a brush head. In another method, bristle tufts that are fused at one end are inserted into holes in the brush neck, and either the neck material is heated to shrink around the bristle tufts, or the brush neck with the inserted bristle tufts are overmolded. However, there are limitations and difficulties with each of these current manufacturing methods such that the manufacturing methods are slow, involve multiple steps and equipment, or have higher than acceptable failure rates, resulting in loose bristles or bristle tufts which can come out of the brush head during use.
- Accordingly, there is a need in the art for methods and apparatus for more efficiently manufacturing brush heads with anchor free tufting.
- The present disclosure is directed to inventive methods for manufacturing a brush head with secured bristle tufts. Various embodiments and implementations herein are directed to manufacturing methods in which a tuft carrier with one or more retention elements and openings formed therethrough is used to retain tufts of bristles. Bristle tuft are then inserted into the openings in the retention elements. Once the bristle tufts have been inserted into the openings in the retention element, optionally, either or both ends of the bristle tufts can be trimmed or adjusted to achieve a desired length and/or contour to what will become the brushing surface of the brush head, and/or to achieve a uniform length of the bristle tufts on the proximal side of the retention element.
- The proximal end of the bristle tufts, or in some arrangements the proximal end of the bristle tufts and proximal side of the retention elements are then bonded together using for example, a laser, heat, chemical interaction or adhesive to form a proximal end head portion or a merged proximal end head portion. Optionally, after cooling from the melting process, at this point, if not done previously, the retention element with melted or merged bristle tufts can be separated into individual merged tuft assemblies.
- Subsequently, a brush neck is positioned in or over a base plate that contains the merged tuft retention element(s). An elastomeric material is injected around a portion of the brush neck and merged tuft retention element(s), which, when cooled, forms an elastomeric matrix that bonds the neck, retention element and melted proximal end of the bristle tufts together to form a brush head. The various embodiments and implementations herein provide a cost-effective and efficient production of brush heads with anchor free bristle tufts is substantially improved.
- Generally, in one aspect, a method for manufacturing a brush head is provided. The method includes forming a plurality of retention elements each having one or more openings therethrough; positioning the retention elements into corresponding recesses of a base plate; inserting a bristle tuft into the opening of each corresponding retention element; bonding a proximal end of each bristle tuft to the corresponding retention element to form a merged proximal end head portion that secures the bristle tufts and the retention elements together as a plurality of merged tuft assemblies; positioning a neck of the brush head in relation to the merged tuft assemblies; and encompassing a platen of the neck and the merged tuft assemblies at least partially in a matrix.
- In one embodiment, the bonding includes applying heat to a proximal side of the retention elements and the proximal end of the bristle tufts at a temperature sufficient to at least partially melt and join the bristle tufts to form the merged proximal end head portion. In one embodiment, the bristle tufts and retention elements are made of a same or similar material having the same or a similar melting point. In one embodiment, the bonding includes laser welding.
- In one embodiment, the forming includes stamping the retention elements from a strip of backing material. In one embodiment, the retention elements are formed as an interconnected web or a carrier plate.
- In one embodiment, the forming includes removing excess material from the retention elements. In one embodiment, the the plurality of retention elements are included by a tuft carrier that comprises a carrier plate, one or more webbing links, or a combination including at least one of the foregoing. In one embodiment, the method further includes stamping the tuft carrier to remove some or all of the carrier plate or the webbing links or to remove excess material to form the carrier plate or the webbing links.
- In one embodiment, the retention elements are not removed from the recesses of the base plate during at least two of the inserting, bonding, positioning, and injecting steps performed sequentially. In one embodiment, the openings in the retention elements are of differing shapes and sizes. In one embodiment, the encompassing includes overmolding the merged tuft assemblies and the platen with the matrix.
- In one embodiment, the encompassing includes injecting the merged tuft assemblies in the form of tuft spikes into the matrix after solidification of the matrix. In one embodiment, the method further includes adjusting characteristics of the proximal end or a free end, opposite to the proximal end, of the bristle tufts.
- Generally, in another aspect, a brush head is provided. The brush head includes a plurality of merged tuft assemblies, each comprising: a bristle tuft comprising a plurality of bristle strands and having a free end and a proximal end; a retention element having an opening therethough configured to receive the bristle tuft; and a merged proximal end head portion formed by bonding the proximal end of the bristle tuft to the retention element; a neck having a platen; and a matrix at least partially encompassing the platen and the retention elements of the merged tuft assemblies.
- It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.
- These and other aspects of the invention will be apparent from and elucidated with reference to the embodiment(s) described hereinafter.
- In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention.
-
FIG. 1A is a perspective schematic representation of a brush head assembly in accordance with an embodiment. -
FIG. 1B is a perspective exploded view of the brush head assembly ofFIG. 1A . -
FIGS. 2A and 2B are cross-sectional side views of schematic representations of merged tuft assemblies according to two embodiments disclosed herein. -
FIG. 2C is a bottom view of a bristle tuft engaged in a retention element of a tuft carrier. -
FIG. 2D is a top view of a merged proximal end head portion of a merged tuft assembly after laser welding. -
FIGS. 3A-3F are schematic representations of tuft carriers according to different embodiments disclosed herein. -
FIG. 4 is a representation of a stamping tool for manufacturing a brush head assembly of the present invention. -
FIGS. 5A-5C show successive steps of using a die block (or handling plate) to stamp out retention elements of a tuft carrier according to one embodiment disclosed herein. -
FIGS. 6A-6B show a handling plate and the handle plate engaged with a tuft carrier according to one embodiment disclosed herein. -
FIGS. 7A-7B show a handling plate and the handle plate engaged with a tuft carrier according to one embodiment disclosed herein. -
FIGS. 8A and 8B show a perspective view and a perspective cross-sectional view of a base plate according to one embodiment disclosed herein. -
FIG. 9 shows a base plate loaded in a tufting unit according to one embodiment disclosed herein. -
FIGS. 10A and 10B are cross-sectional views of a bristle tuft before and after a proximal end of the bristle tuft is trimmed. -
FIGS. 11A-11C illustrate tuft carriers after insertion and bonding of bristle tufts according to various embodiments disclosed herein. -
FIGS. 12A-12C illustrate a base plate having features for adjusting the free end of inserted bristle tufts according to various embodiments disclosed herein. -
FIGS. 13A-13C illustrate a top view and two cross-sectional views of various stages of manufacturing a brush head using a base plate according to one embodiment disclosed herein. -
FIGS. 14A and 14B are a cross-sectional side view and a side view of brush head assemblies according to embodiments disclosed herein. -
FIG. 15 is a flow chart illustrating a method of manufacturing a brush head according to one embodiment disclosed herein. -
FIG. 16 is a perspective schematic representation of a merged tuft assembly having a cap and of a laser welding process using a transparent component. -
FIG. 17 is a flowchart of a method for manufacturing a brush head assembly with bristle tufts retained in a retention element in accordance with an embodiment. -
FIG. 18 schematically illustrates a production line for manufacturing a brush head according to one embodiment disclosed herein. -
FIGS. 19A-19E illustrate a strip of backing material and resultant components at various manufacturing stages according to one embodiment disclosed herein. -
FIG. 20 is a flowchart of a method for manufacturing a brush head assembly in accordance with an embodiment. - The present disclosure describes various embodiments of a method for manufacturing a brush head assembly with bristle tufts retained by anchor free tufting in a retention element secured in a molded elastomeric matrix. More generally, applicants have recognized the need for improvements in manufacturing methods and products made using anchor free tufting. By molding carriers, and in some arrangements, molding carriers from the same or similar material as the bristle tufts, efficiencies in manufacturing are achieved with improved product quality.
- Referring to
FIGS. 1A-1B , in one embodiment, a schematic representation of abrush head assembly 10 is provided. More particularly, thebrush head assembly 10 may include, but is not limited to, a plurality ofbristle tufts 21 disposed within amatrix 30 at a distal end of aneck 40. That is, adistal portion 42 of theneck 40, which may be referred to as a platen, may be at least partially enclosed in and connected to thematrix 30. Theplaten 42 may be, or include, a generally flat portion that provides a hard, rigid, or otherwise reinforcing substrate that is aligned with the bristles of themerged tuft assemblies 20 to support the bristles of thebrush head assembly 10 during use. Themerged tuft assemblies 20 may include atuft carrier 50 having one ormore retention elements 52, in which bristletufts 21 are secured as discussed in more detail herein. Theneck 40 can be coupled to, or form a part of, any manual or powered toothbrush shaft. For example, theneck 40 may be configured to be removably coupled to an actuator or drive shaft (not shown) of a powered oral care device (e.g., electric toothbrush) now known or to be developed. - Two examples for the
merged tuft assemblies 20 are illustrated inFIGS. 2A and 2B , designated asmerged tuft assemblies assemblies merged tuft assemblies 20 are shared throughout embodiments, and thus referred to with the same reference numerals. - Referring to
FIGS. 1-2C , each bristletuft 21 comprises a plurality ofbristle strands 22, which are secured in theretention elements 52 oftuft carrier 50. Each bristletuft 21 has aproximal end 23 and afree end 25. Theproximal end 23 of each bristletuft 21 is retained within anopening 51 of each of theretention elements 52 of thetuft carrier 50, while thefree end 25 is located opposite to theproximal end 23 and forms the brushing surface force thebrush head 10 when assembled. Thebristle tufts 21 can be formed to a shape and diameter to match the size and shape of theopenings 51 in theretention element 52. - It is to be appreciated that the various components of the
brush head 10 may take any desire size, shape, and/or orientation. For example, as seen inFIG. 1A , the retention elements and bristle tufts contained therein can be round, pentagonal, hexagonal, or a variety of other shapes, such as squares, diamonds, heptagons, octagons, etc Additionally, theretention elements 52 and theopenings 51 therein can be of the same size, shape and arrangement as each other, or different shapes and sizes. For example, theretention element 52 may have a first shape defining its periphery, while theopening 51 has a second, different shape defining the shape of thebristle tuft 21 inserted therethrough. - Once the
bristle tufts 21 are inserted in theopening 51 of theretention element 52, theproximal end 23 of thebristle tufts 21, or in some arrangements, theproximal end 23 of thebristle tufts 21 and at least a portion of aproximal side 53 of theretention element 52 are bonded together to form a merged proximalend head portion 26. That is, the mergedproximal head portion 26 may be formed from fused material from thebristles 22 alone, or thebristles 22 together with a portion of theretention element 52 adjacent to thebristles 22. In one embodiment, the bristle tufts and/or theretention elements 52 are bonded together by any suitable process such as welding (ultrasonic, laser, etc.), melting, adhesives, etc. - In order to facilitate formation of the merged
proximal head portion 26 such as shown inFIGS. 2A-2B , thetuft carriers 50 and thebristle tufts 21 are preferably made from the same material, or materials having a similar composition. Plastics such as Acrylonitrile Butadiene Styrene (ABS), polyamide (PA) or nylon, polypropylene, or variations or combinations of these or other materials can be used. Particularly useful are combinations of materials that have a similar co-efficient of melting to facilitate bonding by melting and cooling at a similar temperature and rate. In one embodiment, thebristles 22 are formed from PA, while theretention elements 52 are formed from a PA/ABS blend. It is to be appreciated that there may be some variability across the weld of the merged proximalend head portion 26, e.g., based on the characteristics of the materials of thebristle strands 22 and/or theretention elements 52, as well as the parameters utilized during welding. In particular, variation may occur if thebristle tuft 21 and theretention elements 52 are made of different materials, which may cause melting/cooling at different temperatures, or other differences due to their different chemical compositions. However, such variability is acceptable as long as the desired bonding is achieved. - Advantageously, in one embodiment, a laser welding process is used, which can effectively melt and bond the
bristle tufts 21 andretention elements 52 together to form the mergedproximal head portion 26 as a seal that completely seals across theopening 51 at theproximal end 23 of themerged tuft assemblies 20. For laser welding, the laser concentrates the welding energy more precisely, while enabling more exact application of heat, so that the proximal ends 23 of thebristle tufts 21 and theproximal side 53 ofretention elements 52 melt to from a substantially uniform merged proximalend head portion 26, e.g., as shown inFIG. 2D . - The
tuft carriers 50 and/orretention elements 52 can be formed in a variety of ways, such as molding, stamping, etc., as discussed in more detail herein. Various embodiments for thetuft carriers 50 can be appreciated inFIGS. 3A-3F . The reference numeral ‘50’ as used herein is intended to refer generally to all embodiments of tuft carriers disclosed or envisioned, while alphabetic suffixes (e.g., ‘A’, ‘B’, etc.) have been provided to facilitate discussions of particular embodiments shown in the Figures. A similar naming style may be utilized with respect other components herein. - A
tuft carrier 50A inFIG. 3A comprises a single one of theretention elements 52, which will hold a at least one of thebristle tufts 21 in theopening 51 of theretention element 50A.FIGS. 3B and 3C respectively show atuft carrier 50B and atuft carrier 50C that each comprises acarrier plate 54 having a plurality of theretention elements 52 connected together, e.g., arranged in a shape of the final brush head or some portion thereof. InFIGS. 3D-3F ,tuft carriers tuft carriers 50D-50F comprise a tuft carrier web that has a plurality ofindividual retention elements 52 connected to each other by a series of strands or webbing links 55. In this way, it is to be appreciated that theretention elements 52 can be separate discrete units, or interconnected together, such as by thecarrier plate 54 or the webbing links 55. Similar to thetuft carriers retention elements 52 and/or theopenings 51 of thetuft carriers 50D-50F may be arranged in the desired pattern for thetufts 21 when the brush head is fully assembled, or some portion thereof. - In one embodiment, the
tuft carriers 50 are formed via a molding operation, such as injection molding. The actual shape and size of thetuft carrier 50, the number, size, and shape of theopenings 51, etc., can be set and determined by the mold used to form thecarrier 50. Once thecarrier 50 has been formed and cooled, it can optionally be removed from the mold, and is ready for further processing, either immediately, or at a later time and/or place. - According to embodiments disclosed and envisioned herein, at least a portion of the
tuft carrier 50 may be removed prior to assembly of theretention elements 52 in thebrush head 10. In one embodiment, the removal of excess material is performed by astamping tool 100 shown inFIG. 4 . For example, thestamping tool 100 may include a press, ram, stamp, or die that forcibly engages thetuft carrier 50 placed in a die block or handlingplate 101, as shown inFIG. 5B to cut apart, disconnect, or otherwise separate one or more portions of thetuft carrier 50 from each other. - The
die block 101 or handling plate has a series ofopenings 103 configured to match theretention elements 52 in thetuft carrier 50 in size, shape and arrangement. Namely, theopenings 103 of the die block or handlingplate 101 ofFIGS. 5A-5C corresponds to the size, shape, and layout of thetuft carrier 50C fromFIG. 3C . In this way, as shown inFIG. 5B , theretention elements 52 of thetuft carrier 50C can be inserted into theopenings 103 of the dieblock handling plate 101. The die block or handlingplate 101, together with thetuft carrier 50C, can be loaded into, and stamped by, thestamping tool 100. As shown inFIG. 5C , the stamping operation may disconnect or separate theretention elements 52 fromexcess material 59. Theexcess material 59 may be recycled or discarded, while theretention elements 52 may remain in theopenings 103 of thehandling plate 101, or be removed, for further processing. Thehandling plate 101 may be utilized to facilitate the general handling of thetuft carrier 50 and/or the loading of thetuft carrier 50 into other tools, such as a tufting unit, or other equipment used to create afinished brush head 10. In one arrangement of the present invention, thehandling plate 101 with the tuft carrier therein can be positioned on top of abase plate 110 with openings of similar size and shape in similar positions and the tuft carrier may be transferred from the handling plate into thebase plate 110. It is also noted that some or all of theexcess material 59 oftuft carrier 50 may be removed via other processes, e.g., cutting, or via multiple successive processes, at this step or other steps of the manufacturing process. - To facilitate handling of a variety of
tuft carriers 50 one or more die blocks or handlingplates 101 may be used. A die block or handlingplate 101B, is illustrated inFIGS. 6A-6B . Namely, thehandling plate 101B includesopenings 103B, which correspond in shape, size, and layout to theretention elements 52 of thetuft carrier 50D ofFIG. 3D , as shown inFIG. 6B . Theopenings 103B in thedie block 101B facilitate stamping of thetuft carrier 50D directly into thedie block 101. - Additionally, the
handling plate 101B may include a set of grooves or recesses 104, which are shaped and sized to receive the webbing links 55 of thetuft carrier 50D. In this way, for example, thegrooves 104 may assist in positioning and holding thetuft carrier 50D during manufacturing. It is noted that the handlingplates 101 disclosed and envisioned herein may be removably separated from thebase plate 110 or other components of thestamping tool 100, e.g., to facilitate further processing of the corresponding tuft carrier conveyed by thehandling plate 101. In this way, thehandling plate 101B, together with thetuft carrier 50 stamped into the handling plate, left behind in thegrooves 104, may be separated from the excess material, if desired, for further processing. - A
handling plate 101C according to another embodiment is illustrated inFIGS. 7A-7B . Unlike handlingplate 101B, thehandling plate 101C includes anopening 103C, which corresponds in general shape, size, and/or layout to thecarrier plate 54 of thetuft carrier 50B ofFIG. 3B (as opposed to the individual retention elements 52). In this way, some or all thecarrier plate 54 may remain with theretention elements 52 for various manufacturing steps, and/or may be included in thebrush head 10 during final assembly. For example, in one embodiment, thestamping tool 100 may be configured, with a punch or stamping element to remove only a portion of thecarrier plate 54 so as to change the shape oftuft carrier 50B to the shape of thetuft carrier 50F ofFIG. 3F . In other words, excess portions of thecarrier plate 54 may be removed to leave behind only the webbing links 55. In other embodiments, thecarrier plate 54 may be utilized without removing any excess portions. - In one embodiment, the
tuft carrier 50 is formed by overmolding thetuft carrier 50 directly onto thecorresponding handling plate 101. In this way, thehandling plate 101, together with the unprocessed instance of thetuft carrier 50, can be directly placed on thebase plate 110 and processed by manufacturing equipment, e.g., stamped by thestamping tool 100. The handlingplates 101 may be made of any desired material, such as a metal or other rigid material to facilitate handling of thetuft carrier 50 when engaged with thehandling plate 101, as well as to promote reusability of thehandling plate 101 for multiple stampings or other manufacturing processes. - One embodiment for a
base plate 110 is shown inFIG. 8A and cross-sectionally inFIG. 8B . Thebase plate 110 includes a recessedarea 111 configured to receive the handlingplates 101 or other manufacturing plates as discussed herein (as shown inFIG. 9 ). In this way, according to one embodiment, thebase plate 110, together with thehandling plate 101 placed in the recessedarea 111, can be used during stamping to stamp theretention elements 52 directly into correspondingopenings 109 in thebase plate 110. - The
base plate 110 inFIG. 8B is also illustrated having theretention elements 52 already inserted in theopenings 109, via stamping as discussed above, or by some other process such as manual insertion. As noted above, thetuft carrier 50 may compriseindividual retention elements 52, such as shown inFIG. 8B , or the tuft carrier 50 b, 50 c, may comprise a plurality of theretention elements 52 connected by thecarrier plate 54, of the tuft carrier 50 d, 50 e, 50 f, may comprise a plurality theretention elements 52 connected by webbinglinks 55. - As shown in
FIG. 8B , thebase plate 110 hasopenings 109 that correspond to each of theopenings 51 in theretention elements 52. Note that the diameter or dimensions of theopenings 109 may be configured such that theretention elements 52 are held by thebase plate 110 in a desired position (e.g., theopenings 109 may be tapered from top to bottom). The configuration of theopenings 109 is useful for defining the shape, length, configuration, and cross-sectional shape of thebristle tufts 21 that will be inserted during subsequent steps of the manufacturing process. As discussed in more detail below, thebase plate 110 may include an adjustment feature configured to assist in defining the length and/or contour of the free ends 25 of thebristle tufts 21, such as acontour insert 114. -
FIG. 9 illustrates atufting unit 130 according to one embodiment. Thetufting unit 130 may be provided operated to form a plurality of thebristle strands 22 into thebristle tufts 21, which are inserted into each of the plurality ofopenings 51 in theretention elements 52, as shown inFIG. 10A . For example, as shown inFIG. 9 , thetufting unit 130 may include atuft inserter 132 that can be aligned with a correspondingopenings 103 in ahandling plate 101 that is inserted in the base plate 110 (e.g., held in the recessed area 111). The die block or handlingplate 101 includes a plurality ofopenings 103 therethrough. Theopenings 103 in thehandling plate 101 are aligned with theopenings 51 in thetuft carrier 50, and theopenings 109 in thebase plate 110. When thevarious openings handling plate 101,tuft carrier 50 andbase plate 110 are aligned, in operation, thetufting unit 130 forcibly injects the bristles therein (e.g., mechanically, via pressurized air, etc.) to formbristle tufts 21 of a shape and size that corresponds with the openings. It is to be appreciated that thehandling plate 101 may be a die plate, a guide plate, or a different plate. It is noted that tufting may occur prior to the aforementioned stamping or cutting of tuft carriers, if desired. - As can be appreciated, the
bristle tufts 21 must be of the proper shape, size, and diameter to fit into each respective opening. The ends of thebristle tufts 21 that are inside thebase plate 110, as shown inFIG. 10A , will become thefree end 25 of thebristle tufts 21 in thebrush head assembly 10, while the portion of thebristle tufts 21 that project above thebase plate 110, such as shown inFIG. 9 , will become theproximal end 23 of thebristle tufts 21. - After tufting, the proximal ends 23 of the
bristle tufts 21, may optionally need to be trimmed to a uniform height to ensure a proper sealing during the subsequent bonding step. To perform trimming, as shown inFIG. 10A , a cuttingplate 116 having a height H can be placed in therecess 111 on thebase plate 110 at theproximal end 23 of thetuft 21. The cuttingplate 116 may be the same plate as thehandling plate 101, or may be a different plate. A knife or cutting implement 117 can be used to trim the length of thebristle tuft 21 by removing the excess portion of thebristle tuft 21 protruding above theplate 116. In this way, as shown inFIG. 10B , the length ofbristle tuft 21 extending out from aproximal side 53 of theretention element 52 will approximately equal the height H of theplate 116 when theplate 116 is removed. For example, this preset length of theproximal end 23 of thebristle tuft 21 can be useful to assist the consistent and predictable creation of the proximalend head portion 26 during bonding. - After tufting, the proximal ends 23 of the
bristle tufts 21 can be bonded to theproximal side 53 ofretention elements 52, e.g., by melting, welding, adhering, or other technique, to form the merged proximalend head portion 26 as noted above with respect toFIGS. 2A-2B and also shown inFIGS. 11A-11C . Three different examples of thetuft carriers 50 after tufting are shown inFIGS. 11A-11C . More particularly,FIG. 11A illustrates thetuft carrier 50D tufted with thebristle tufts 21, which extend into openings of thebase plate 110.FIG. 11B illustrates thetuft carrier 50B tufted with thebristle tufts 21 while carried by thehandling plate 101C.FIG. 11C illustrates thetuft carrier 50A (a single one of the retention elements 52) with thebristle tuft 21 melted to form a merged proximalend head portion 26 from at least a portion of thebristle tuft 21 and a portion of the proximal end of theretention element 52. - In one embodiment, bonding is accomplished by melting the
bristle strands 22, alone or together with a portion of theretention element 52. Heat can be supplied by a heat source that comes into direct physical contact with theproximal end 23 of the bristle tufts and/or theproximal side 53 of theretention elements 52, such as a laser. Alternatively, the heat can be supplied by heated air or any of a variety of other heat sources that can be in direct physical contact, merely adjacent, or directed. As noted above, forming thebristle strands 22 and theretention elements 52 from the same or a similar material composition, may advantageously improve bonding by utilizing a same or similar melting point. - Several embodiments of features to enable adjustment of the characteristics of the
free end 25 of thebristle tufts 21 can be appreciated in view ofFIGS. 12A-12C . InFIG. 12A , tuft bores 112 are arranged as blind holes that terminate within thebase plate 110. As discussed above, the bottom surface of the blind holes can be set as a predefined distance fromopenings 109, in which theretention elements 52 are be seated during tufting. That is, the bottom of each blind hole provides a stop for the portion of thebristle strands 22 that will ultimately become thefree end 25 of thebristle tufts 21 in the completed brush head so that thebristle tufts 21 are maintained at the proper length during the manufacturing process. The blind holes also support thebristle strands 22 during the manufacturing process when thebristle strands 22 are inserted (e.g., via the tufting unit 130). In addition to length, the tuft bores 112 arranged as blind holes can be set to different shapes, sizes, or contours. For example, a firstblind hole 118A is illustrated as slightly larger in diameter than the others, while a secondblind hole 118B is illustrated as slightly shorter than the others and with a curved bottom surface to create a curved contouring for thefree end 25 of thebristle tuft 21 that is inserted into theblind hole 118B. - The
base plate 110 inFIG. 12B is illustrated as including acontour insert 114 also shown inFIG. 8B . As previously noted, thecontour insert 114 may be used to define the shape of thefree end 25 of thebristle tufts 21 in thebrush head assembly 10. For example, thecontour insert 114 shown inFIG. 12B would generate a finished brush head that has a shape of bristle tufts that vary in length and surface angle, as set by thetufts 21 engaging against asurface 114 a of thecontour insert 114. It can be appreciated that other shapes, such as a flat brushing surface, e.g., in which the free ends 25 of all thebristle tufts 21 project out the same distance, can also be achieved, based on the shape of thecontour insert 114 that is used. Thecontour insert 114 may be arranged as a removable and interchangeable component so a variety of desired shapes of completed brush head bristles can be achieved with thesame base plate 110. - In another arrangement shown in
FIG. 12C , each of the tuft bores 112 may be provided with apin 116 of the same shape and diameter as the tuft bores 112. For example, thepins 116 may be movable within the tuft bores 112 to enable the length of the tuft bores 112 to be adjustably set. Pins having different surface angles can be included to change the contouring of the brushing surface resulting from the free ends 25. Thus, it is to be appreciated that thepins 116 generally serve the same purpose and function as thecontour insert 114 and the blind holes 118, e.g., to form the desired shape, length, and contours of the bristle field and/or brushing surface of the completed brush head. - Final assembly of the
brush head 10 can be appreciated in view ofFIGS. 13A-13C .FIG. 13A shows a top view of thebase plate 110 having the tuft bores 112 and therecesses 109 formed therein as described above, i.e., for receiving thebristle tufts 21 and theretention elements 52, respectively. In this way, after stamping, tufting, bonding, etc., themerged tuft assemblies 20 are fully formed, and can be positioned with theretention elements 52 in therecesses 109 and the free ends 25 of thebristle tufts 21 in the tuft bores 112. - The
base plate 110 may also include a recess orcavity 120 in the general shape of thebrush head 10neck 40 and/or thematrix 30. After themerged tuft assemblies 20 are are created and positioned in thebase plate 110, theneck 40 may be positioned to align theplaten 42 in relation to the merged proximalend head portions 26 of themerged tuft assemblies 20. For example, as shown inFIG. 13B , thecavity 120 may properly align theplaten 42 of theneck 40 with thetuft assemblies 20 when theneck 40 is placed in thecavity 120. Additionally, any desired prefabricated parts (e.g., electronic parts, additional rings, springs, or any other components) can be added and held in position by thebase plate 110 during this step of manufacturing. Any such parts can be molded into the final brush head as described in subsequent steps herein. - Thereafter, the components may be overmolded by the
matrix 30 by injecting material, e.g., in a liquid or flowable state, into the space formed between theplaten 42 and the merged proximalend head portions 26 of themerged tuft assemblies 20. Thematrix 30 solidifies to secure theneck 40 and thetuft assemblies 20 together by at least partially encompassing or encapsulating theplaten 42 and thetuft assemblies 20, as shown inFIG. 13C , thereby forming thebrush head assembly 10. According to an embodiment, thematrix 30 is preferably made from an elastomeric material such as a flexible thermoplastic elastomer (TPE) or silicone rubber. It is to be appreciated that in one embodiment theneck 40 is not provided as a pre-formed member, but instead that thematrix 30 and theneck 40 are formed at the same time and by the same material by injecting a suitable material into thecavity 120.FIGS. 14A and 14B respectively illustrate additional examples of thebrush head 10 when completed. - Referring to
FIG. 15 , in one embodiment, is amethod 200 for manufacturing one or more of the variousbrush head embodiments 10 and implementations described or otherwise envisioned herein. Instep 210, atuft carrier 50 is formed, such as by molding by any known molding process. The tuft carrier includes one ormore retention elements 52 having anopening 51 formed therethrough. - In step optional 220 of the
method 200, the tuft carrier may be processed to alter, set, or define the size or shape of the tuft carrier, or the retention elements or openings therethrough. For example, the tuft carrier may be stamped or cut to removeexcess material 59. For example, the tuft carrier may be acarrier plate 54 further processes so that one ormore webbing links 55 that are formed, shaped, resized, or removed in the step 220 (e.g., with thestamping tool 100, thehandling plate 101, or as otherwise discussed with respect toFIGS. 4-7B ). - At
step 230, the retention elements of the tuft carrier, either directly after formation instep 210, or after processing instep 220, are positioned in correspondingrecesses 109 of ahandling plate 110. In one embodiment, thesteps FIGS. 4-7B ). - At
step 240 of themethod 200, bristles are arranged in tufts and inserted (e.g., via the tufting unit 130) through theopenings 51 in theretention elements 52. Atoptional step 250, aproximal end 23 and/or afree end 25 opposite to the proximal end of thebristle tufts 21 may be adjusted in length, shape, size, contour, etc. For example a base plate may include an adjustment feature such as an insert having a contouredsurface 114, or blind holes 118 and pins 119 for receiving and setting the contour of the free ends. The proximal ends of the bristle tufts may optionally be cut or trimmed to achieve a desired height using acutting plate 116 and a knife or cutting implement 117. - At
step 260 of the method, theproximal end 23 of thebristles 22 of thebristle tufts 21 are bonded together and/or bonded to at least a portion of the proximal side of theretention element 50 to form a merged proximalend head portion 26. Once secured together by the merged proximalend head portion 26, each corresponding pair of the bristle tufts and the retention elements form amerged tuft assembly 20. In one embodiment, bonding is achieved by applying heat to the proximal end of the bristle tufts and the retention elements to melt the components together. The heat can be supplied by a heat source that comes into direct physical contact with the proximal end of the bristle tufts and/or the retention elements. Alternatively, the heat can be supplied by heated air or any of a variety of other heat sources that can be in direct physical contact, merely adjacent, or directed. By making the bristle strands and the retention elements from material having the same or a similar composition, and therefore the same or similar melting point, good bonding can be facilitated. - At
optional step 270, if not already done previously in the manufacturing process (e.g., at step 220), the tuft carrier can be processed to remove any excess material. For example, as discussed above with respect to step 220, this may include removing a portion or all of a carrier plate, webbing link, etc. As also discussed above,step 270 may not be performed, e.g., if the entirety of thecarrier plate 54 is included in thebrush head assembly 10 when fully assembled. - In
step 280 of themethod 200, the tuft assemblies can be inserted into the base plate (if not already installed) and aneck 40 for the brush positioned relative to the tuft assemblies. For example, this may include placing the neck in acorresponding cavity 120 of the base plate, which aligns aplaten 42 portion of theneck 40 with respect to the merged tuft assemblies. After positioning, amatrix material 30 is overmolded about at least a portion of the merged tuft assemblies and the neck by injecting material into the space between the neck and the merged tuft assemblies. The matrix may include an elastomeric material. Once solidified, the matrix at least partially encompasses or encapsulates the merged tuft assemblies and the neck together, thereby forming the brush head assembly. - In accordance with embodiments disclosed and envisioned herein, it is to be appreciated that the same handling plate or base plate (101, 110) may be utilized for multiple different manufacturing steps, such as molding, stamping, tufting, bonding, trimming/adjusting bristles, and/or overmolding. In other embodiments, partially-manufactured components may be transferred from one handling plate or base plate to a different handling plate or base plate. Additionally, it is to be appreciated that each of the steps in
method 200 are optional and/or may be completed in an order other than that shown. Advantageously, these features enable flexibility in the time and location for any of the manufacturing steps, while also permitting each step to immediately follow the next if desired. - As noted herein, laser welding may be particularly advantageous in some embodiments for bonding the bristles and retention elements together. Laser welding will consume at least a portion of the
proximal end 23 of thebristles 22 as well as adjacent portions of theretention elements 52 in forming the mergedproximal head portion 26 as a completely sealed unitary element. The laser welding can accordingly be operated at some pre-specified performance characteristics (e.g., laser beam wavelength, resultant temperature of the heated materials, pulsation frequency or duration of continuous operation, beam diameter, speed at which the beam is moved across theproximal end 23, etc.) to melt the corresponding materials to a predictable depth and/or with a predictable depth profile(s) across the width (lateral/radial direction) of each of thetuft assemblies 20. - Laser welding operations may be configured with respect to one or more weld zones. The weld zones may include a first weld zone adjacent the
proximal side 53 of theretention element 52, in which only material from theretention element 52 is melted and reformed, i.e., without integrating any of thebristle strands 22 therein. A second zone may be formed laterally or radially inward of the first zone, in which both a portion of theretention element 52 and thebristle strands 22 are melted and integrated together. A third zone may be formed where only thebristles 22 are melted and integrated together, i.e., without integrating any material from theretention element 52. - If compatible materials are used, the second zone can advantageously fuse together materials from both the
retention elements 52 and thebristles 22 and assist in integrating the first and third zones together as a continuous, unitary, sealed structure, e.g., the mergedproximal head portion 26. Any of the weld zones discussed above may be formed to preselected dimensions (e.g., lateral distance and/or longitudinal depth) and/or with some preselected dimensional profile(s) in the corresponding zone, e.g., a gradient laterally/radially across thetuft assembly 20 and/or across any of the zones. The third zone (including just the material from the bristles 22) is expected in many embodiments to be the largest zone, depending on the cross-sectional size of thetufts 21 and the thickness of theretention elements 52. - The selected welding energy or energies, the area/volumes to which the energy/energies are directed, the duration the energy/energies are applied, and other parameters may be varied across the
tuft 21 or thetuft carrier 50 and/or across a particular tuft of aparticular retention element 52 of thetuft carrier 50. As to any carrier, the parameters of the welding may be configured so as to provide strong, complete, sealed and otherwise desired welds for each tuft-retention element. For example, particular welding parameters may be adjusted to respond to one or more of various factors, such as: (a) desired shape/dimensions of a weld to set a tuft retention force enabled by the weld and other structural and performance goals relating to the weld; (b) a tuft's shape, dimensions, size, etc.; (c) a tuft carrier or retention element shape, dimensions, size, etc.; (d) alignment/orientation of a tuft with respect to its retention element (e.g., the distance(s), such as the height H, that filaments protrude from the proximal end of the retention element); (e) the alignment/orientation of the tuft carrier or tuft-retention element to the platen, e.g., to set performance characteristics of the tufts after final assembly of the brush head; (f) filament(s) shape, structure(s), type, materials, etc.; and/or (g) the carrier/retention element's shape, structure(s), type, materials, etc. The welding configuration may be optimized, e.g., to arrive at desired and proper welds in a minimum or otherwise desired amount of time, or energy (e.g., to minimize or prevent burning or other activity that might change the nature of the weld or any material). - One or more selected welds may be performed by introducing an auxiliary material to selected area of the welding. As an example, an auxiliary material may be introduced at the proximal end of selected or all filaments so that, with welding, a weld is provided that combines the
bristles 22 with the auxiliary material and theretention element 52 in locations sufficiently proximate to theretention element 52. The introduction of the selected material may be accomplished by applying the auxiliary material, e.g., as a thread, powder, liquid, etc. to the welding area in a selected mass or volume during welding. The auxiliary material may be the same or similar material as thebristle strands 22, or theretention element 52, some combination of these, or neither of these. - In one embodiment, for example, as shown in
FIG. 16 , one or more plates, caps, coverings, coatings, or other solid volumes comprising a defined amount of an auxiliary material may be applied on, over, or adjacent the selected area(s) for welding. For example, in the case of a plate, its selected area may provide for it to extend beyond the tuft perimeter (e.g., laterally or radially) so as to cover the merged proximalend head portion 26. In this way, after welding, the plate forms acap 27, as shown inFIG. 16 , which covers all, or substantially all, of the merged proximalend head portion 26 of theretention element 52 and thetuft 21 after welding. By this or other manner of introducing auxiliary material across the intended welding area, for example, the seal provided by the welding may be enhanced, e.g., so as to impede or prevent incursion of other materials between thebristles 22 and/or theretention element 52 during subsequent overmolding or other assembly processes. - In one embodiment, the laser welding process is performed using a plate or material that is transparent to the beam of the laser. In this transmission welding technique, the laser may pass through the plate so as to weld the tuft and retention element and, in so doing, generate thermal energy sufficient to join the plate to the
retention element 52 and/or thetuft 21. The plate may be placed over the merged proximalend head portion 26 with clamping pressure applied. For example, referring toFIG. 16 , thecap 27 may be made from a material that is transparent to abeam 99 from a laser device, such that thebeam 99 passes through thecap 27 and melts thebristle tuft 21 and/or theretention element 52 together at anouter surface 26′ of the merged proximalend head portion 26. The heat generated at theouter surface 26′ can be sufficient to also bond thecap 27 to thebristle tuft 21 and/or theretention element 52, thereby sealing and/or forming a part of the merged proximalend head portion 26. - Referring to
FIG. 17 , in one embodiment, is amethod 300 for manufacturingmerged tuft assemblies 20 according to the embodiments and implementations described or otherwise envisioned herein. It is to be understood that the steps of themethod 300 may be generally interchanged, or inserted, as applicable, with or between the steps of other methods disclosed herein, such as themethod 200. Likewise, the steps of other methods disclosed herein may be interchanged and/or inserted into themethod 300. Instep 310 of themethod 300, atuft carrier 50 comprising one ormore retention elements 52 is provided. Atstep 312 of themethod 300, a plurality ofbristle tufts 21 are provided, each of which comprises a plurality ofbristle strands 22. - At
step 320 of themethod 300, at least one of the bristle tufts is inserted into anopening 51 of each of the retention elements of the tuft carrier. Atstep 330, the length, contouring, or configuration of aproximal end 23 or afree end 25 of the bristle tufts may be trimmed or otherwise adjusted (e.g., as discussed with respect to step 250 of the method 200). - At
step 330, a laser is utilized to weld the proximal end of the bristle tuft, or the proximal end of the bristle tuft and at least a portion of theproximal side 53 of the retention element together. When cooled or otherwise solidified, the laser welding creates aproximal head portion 26. Step 330 may include adding an auxiliary material (e.g., the cap 27) to assist in creating or sealing the weld. - After the proximal end head portion of the welded tuft assembly has been formed and allowed to cool, the welded tuft assembly can be further processed, either immediately thereafter or at another place and time. For example, in one embodiment, the welded tuft assemblies can be positioned relative to a neck of a brush head (e.g., the neck 40) and overmolded, together with the neck, by a matrix (e.g., the matrix 30) to form a completed brush head (e.g., the brush head 10).
- As noted herein, the
tuft carriers 50 may be formed by stamping. Accordingly, amanufacturing production line 150 for manufacturing brush heads, e.g., thebrush head 10, utilizing stamping is illustrated inFIG. 18 . Various steps or stages employed by theproduction line 150 are also best appreciated inFIGS. 19A-19E , which are marked with the corresponding stage number fromFIG. 18 in brackets. At stage [1], theproduction line 150 is provided with abacking material 60 in a blank form. Thebacking material 60 may be provided from aroll 151, or in some other form such as a strip 151 a, plate, etc. (not shown). As discussed in more detail below, thebacking material 60 may have a width and thickness sufficient from which to produce theretention elements 52. Thebacking material 60 may be formed as a length of material such thatretention elements 52 for a number of brush heads may be successively produced from the same piece of backing material, e.g., as thebacking material 60 is unspooled from theroll 151, or a strip of backing material 151 a (not shown) is fed to the manufacturinc equipment. In some arrangements, thebacking material 60 may have one or more guide holes 61 to assist in transitioning thebacking material 60 between the different pieces of manufacturing equipment, and/or to keep thebacking material 60 at the proper position and tension on the manufacturing equipment, e.g., by engaging theholes 61 with corresponding pins of the manufacturing equipment. - At stage [2], a plurality of
openings 62 is stamped through thebacking material 60. As can be seen inFIGS. 19A-19C , different sizes, shapes and placements ofopenings 62 can be stamped into thebacking material 60. In this way, theopenings 62 may each, and/or together, be arranged in sizes, shapes, and/or patterns to reflect the planned arrangement ofbristles tufts 21 in thebrush head assembly 10 when completed. As will be better appreciated in view of the below disclosure, theretention elements 52 are formed from thebacking material 60 with eachopening 62 providing a means for inserting a bristle tuft therethough so that the bristle tuft may be secured with or to through theretention elements 52. Stage [2] may be carried out using a die and/or stampingpress 152. If different final bristle configurations are desired, different stamp dies can be used for the various configurations. - During stamping, the
backing material 60 and/or portions thereof may be engaged in or on a mold or basedplate 110. Once thebacking material 60 has been stamped, it is ready for further processing, either immediately, or at a later time and/or place. If at a later time and/or place, the stampedbacking material 60 can be rolled or stacked and unrolled or unstacked again later for further processing on the same or different manufacturing equipment. Thebacking material 60 may stay in the mold (e.g., the base plate 110) during multiple stages, or may be transferred between different molds (e.g., the base plate 110), e.g., specifically arranged for each stage, as desired. - At stage [3], one or
more bristle tufts 21 are inserted into the plurality ofopenings 62 in thebacking material 60. As can be appreciated, each bristletuft 21 must be of the proper size to fit into eachrespective opening 62 and/or the size and shape of theopenings 62 define the respective shape and size of the corresponding bristletuft 21 when theopenings 62 are filled with thebristle strands 22. - The
proximal end 23 andfree end 25 may be adjusted via any manner described herein, e.g., via a contour plate, pins, blind holes, cutting plate, knife, etc. For example, inFIGS. 19A-19B , a portion of thetufts 21 is illustrated as protruding from aproximal side 63 of thebacking material 60 at stage [3], and this protruding portion is removed at stage [3.1]. In one embodiment, the protruding portion may be trimmed to a predetermined height, e.g., in order to facilitate later bonding processes, particularly melting or other processes that tend to partially consume the bristlestrands 22 during bonding. The cutting or trimming of thebristles 22 may be accomplished by a knife or other cutting tool, e.g., running along the surface of theproximal side 63 of thebacking material 60. - At stage [4], the proximal ends 23 of the plurality of
bristle tufts 21 are bonded together, which may include bonding thetufts 21 with or to at least a portion of thesurrounding backing material 60. For example, sufficient heat to melt the components together may be applied to form the merged proximalend head portion 26 as discussed above with respect toFIG. 2 . Thus, it is to be appreciated that the merged proximalend head portion 26 may be formed as a combination of one or more of at least a portion of theproximal side 63 of thebacking material 60 and at least a portion of theproximal end 23 of thebristle tufts 21 merged together. Bonding can be achieved using aheat source 155, such as a heated press, ram, or pin, which comes into direct physical contact with theproximal end 23 of thebristle tufts 21 and/or theproximal side 63 of thebacking material 60. Alternatively, bonding cana be achieved using heated air, a welding laser, chemical fusing, or a variety of any other heat source. As noted above, in order to form amerged tuft assembly 20, thebacking material 60 and bristletufts 21 may be made of material having the same or a similar composition, such as ABS, nylon, polypropylene, or variations or combinations of these materials. - At stage [5], once the merged proximal
end head portion 26 is formed (and has cooled or cured sufficiently), in one arrangement of the present invention,excess portions 64 of thebacking material 60 may be removed, e.g., by stamping or cuttingequipment 156 to form individualmerged tuft assemblies 20. As illustrated, instead of separate merged tuft assemblies, atuft carrier web 28 may be formed as a group of thetuft retention elements 52 interconnected by strands or webs (e.g., in the final bristle tuft pattern for the brush head 10). Enlarged versions of thetuft retention elements 52 and/or thetuft carrier web 28 at stage [5] is illustrated inFIG. 19D . Stage [5] may include a pre-cutting operation in which thetuft retention elements 52 and/or thetuft carrier web 50′ is still attached to thebacking material 60 via one or more strands or webs. In one embodiment of the present invention, stage [5] of manufacturing is not utilized. In this embodiment, instead of forming thetuft carrier web 28 by removing theexcess portions 64, acarrier plate 29 of merged tuft assemblies is created, as best shown inFIG. 19C at stage [4]. In this embodiment, manufacturing proceeds from stage [4] directly to stage [6], and thecarrier plate 29 of merged tuft assemblies is removed from the backing material, 60 as described below. - At stage [6], individual
merged tuft assemblies 20 and/ortuft carrier webs 28 of merged tuft assemblies, orcarrier plates 29 of merged tuft assemblies may be completely removed from thebacking material 60. An enlarged view of thetuft carrier web 28 is shown inFIG. 19E . Once the completed merged tuft assemblies 20 (either separate or interconnected in thetuft carrier web 28 or tuft carrier plate 29) are separated from thebacking material 60, the surplus backing material remaining on the roll can be disposed of or recycled in stage [10], as known in standard industrial recycling techniques. - In stage [7], the
neck 40 is formed according to any desired known or future developed standard manufacturing technique, e.g., by molding theneck 40 from plastic using a mold. In stage [8], theneck 40 and the merged tuft assemblies 20 (e.g., separately or in one of thetuft carriers 50 such as thetuft carrier web 28 or tuft carrier plate 29) are positioned relative to each other and overmolded by thematrix 30. - It is to be appreciated that variations on the above-described manufacturing processes are possible. For example, the above-discussed steps and stages may be optionally performed, performed in a different order, or substituted for other steps or stages. In one embodiment, the
backing material 60 is stamped in such a way, e.g., at stage [2], such that theexcess portions 64 of thebacking material 60 are removed prior to tufting. In this way, thetuft retention elements 52 and/or thetuft carrier web 50′ are tufted and then bonded to the tufted bristles, instead as described above. In one embodiment, theretention elements 52, thetuft carrier web 28, orcarrier plate 29 can be completely cut out of the backing material 60 (e.g., as discussed with respect to stages [5-6]), and further processing (e.g., insertion of bristle tufts in accordance to stage [3], bonding or melting in accordance with stage [4], over molding in accordance with stage [8], etc.), can be completed (e.g., after cutting them out from thebacking material 60, theretention elements 52 and/or thecarrier web 28 orcarrier plate 29 may be maintained in the same mold until completion). In other embodiments, the partially-processedbacking material 60 may be transferred between different molds or pieces of equipment at the same or different locations, facilities, and/or times. - Referring to
FIG. 20 , amethod 400 is provided for manufacturing one or more of thevarious brush head 10 embodiments and implementations described or otherwise envisioned herein. As with the other methods disclosed herein, it is to be understood that the steps of themethod 400 may be generally interchanged, or inserted, as applicable, with or between the steps of other methods disclosed herein, such as themethods method 400. - In
step 410 of themethod 400, a strip 151 a or roll 151 of backing material is provided as described with respect to stage [1] above. Instep 420, a plurality ofopenings 62 is formed through the backing material of a size, shape and pattern to reflect the planned arrangement of bristles in the completedbrush head assembly 10 as described with respect to stage [2] above). - In one embodiment, optionally, at
step 430, the backing material is stamped or cut in such a way thatexcess portions 64 of the backing material are removed to form one or more separatetuft retention elements 52 and/or an interconnected web oftuft retention elements 28. The retention elements and/or carrier web may be completely cut out of the backing material before subsequent processing. Once the backing material has been stamped (either to form just the openings or both the openings and the retention elements and/or carrier web), it is ready for further processing, either immediately, or at a later time and/or place. - At
step 440 of themethod 400, abristle tuft 21, comprising a plurality of thebristle strands 22, is inserted into each of the openings formed instep 420. In some embodiments, atstep 450 theproximal end 23 and/or thefree end 25 of the bristle tufts may be trimmed or adjusted to a set a desired length and/or contouring (e.g., using the contouring plate as discussed herein). - At
step 460 of themethod 400, the bristles are bonded. For example, thestep 460 may include applying heat to the proximal end of the plurality ofbristle tufts 21 to melt the bristles and/or the bristles and the backing material together to form a proximalend head portion 26. Alternatively, laser welding, adhesives, or other bonding techniques may be used for the bonding step. -
Optional step 470 resemblesoptional step 430 and may be performed ifstep 430 was not performed previously. That is, atstep 470, once the merged proximal end head portion of the merged tuft assembly is formed, excess portions of the backing material can be removed to form separate tuft retention elements and/or an interconnected group of tuft retention elements arranged in a tuft carrier web. Instep 480 of themethod 400, the completed tuft retention elements and/or tuft carrier web can be cut out of the backing material. It is noted that thestep 480 may occur directly after, or as part of, thestep 430 if desired. - In
step 490 ofmethod 400, a platen portion 43 of abrush head neck 40 is positioned in relation to themerged tuft assemblies 20 by placing thetuft carrier assemblies 20 as described above. Amatrix 30 can then be injected into the space created between the tuft carrier assemblies and the neck of the brush head. The matrix, when solidified, encompasses or encapsulates at least a portion of the neck and the merged tuft assemblies, to form the completed brush head assembly (e.g., thebrush head 10 as shown inFIG. 1A ). - All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.
- The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”
- The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified.
- As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.”
- As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.
- It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.
- In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.
- While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.
Claims (15)
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US16/761,570 US11571061B2 (en) | 2017-11-07 | 2018-06-20 | Brush head manufacturing method, and brush head |
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US16/761,570 US11571061B2 (en) | 2017-11-07 | 2018-06-20 | Brush head manufacturing method, and brush head |
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US11571061B2 US11571061B2 (en) | 2023-02-07 |
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CN114145560B (en) * | 2021-12-08 | 2023-05-12 | 深圳市一晤未来科技有限公司 | Preparation method of brush head assembly |
CN114145561B (en) * | 2021-12-08 | 2023-05-12 | 深圳市一晤未来科技有限公司 | Preparation method of brush head with retainer |
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US3069524A (en) | 1958-11-12 | 1962-12-18 | King Seeley Thermos Co | Electro-responsive heating system |
JP2000507120A (en) * | 1996-02-21 | 2000-06-13 | コロネット―ベルケ・ゲゼルシャフト・ミット・ベシュレンクテル・ハフツング | Method of manufacturing brush-like products such as brushes |
GB9620092D0 (en) | 1996-09-26 | 1996-11-13 | Unilever Plc | A brush and method for producing same |
US6220673B1 (en) | 1999-07-12 | 2001-04-24 | Colgate-Palmolive Company | Laser joining toothbrush heads to handles |
DE10221786A1 (en) | 2002-05-15 | 2003-11-27 | Schiffer Fa M & C | Toothbrush construction comprises plastic layers of different hardness with bristles embedded in one layer and passing through the other |
DE20301634U1 (en) | 2003-02-03 | 2004-06-09 | M + C Schiffer Gmbh | A tooth brush with a bristle group, a bristle head with a holding channel for a surface element carrying the bristle groups generally useful for maintenance of oral hygiene |
DE20303934U1 (en) * | 2003-03-12 | 2004-07-22 | M + C Schiffer Gmbh | Device for making a brush |
DE102008029499A1 (en) * | 2008-06-20 | 2009-12-24 | M + C Schiffer Gmbh | Brush, in particular toothbrush and method for its manufacture |
DE102010025852A1 (en) * | 2010-07-02 | 2012-03-29 | Gb Boucherie Nv | Method and apparatus for making brushes |
BR112013016681A2 (en) | 2011-01-04 | 2016-10-04 | Trisa Holding Ag | toothbrush, method for producing a toothbrush, and apparatus for producing a toothbrush |
KR101346040B1 (en) * | 2011-02-24 | 2013-12-31 | 최의정 | Toothbrush |
US9357831B2 (en) | 2012-02-24 | 2016-06-07 | Vikan A/S | Hygienic brush head |
CN106413470B (en) * | 2014-03-25 | 2019-09-13 | 皇家飞利浦有限公司 | Brush head device |
EP3700386A1 (en) | 2017-10-24 | 2020-09-02 | Koninklijke Philips N.V. | Brush head manufacturing methods using a molded tuft carrier and base plate |
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- 2018-06-20 WO PCT/EP2018/066335 patent/WO2019091603A1/en unknown
- 2018-06-20 CN CN201880085362.1A patent/CN111556719B/en active Active
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RU2020118871A3 (en) | 2021-12-08 |
JP7219764B2 (en) | 2023-02-08 |
RU2020118871A (en) | 2021-12-08 |
WO2019091603A1 (en) | 2019-05-16 |
EP3706597A1 (en) | 2020-09-16 |
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